Replacing injection pump throttle lever return spring: VW 2.4 D (AAB, AJA)
Step-by-step replacing injection pump throttle lever return spring for the VW 2.4 D (AAB/AJA): factory workshop text.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📐 23 workshop diagrams for AAB
Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.
📋 Procedure
ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.
AJA
Special tools, testers and auxiliary items
Torque wrench V.A.G 1331 (5...50 Nm)
Ignition tester V.A.G 1767 or V.A.G 1367
Note:
The items referred to without illustration refer to the exploded view V23-0224, Page
23-42
.
Removing
Check that idling speed and engine governed speed are as specified; adjust if necessary.
Vehicles 09.94▸
Removing radiator grille:
=> General body repairs; Repair group 66; Servicing radiator grille
General body repairs
Servicing radiator grille
Continued for all vehicles
Unbolt left and right-hand securing bolts -1-.
Note:
Vehicles 09.94▸one securing bolt is located on each left and right-hand side on lock carrier.
Fold lock carrier with radiator out forwards -arrow-.
Disconnect throttle cable.
Note:
When removing and installing the throttle lever, ensure that the position of the throttle lever relative to the throttle lever shaft is not altered. In some cases there are line marks on the throttle lever shaft and the throttle lever -arrows-.
Remove circlip from damper and remove damper from throttle lever.
Detach return spring -8-.
Loosen securing nut -4-.
Remove throttle lever -6- and return spring -8- with spring plates -7-.
Installing
Install return spring -8- together with spring plates -7-.
Install throttle lever -6- in marked position.
Fit washer -2- and spring washer -5-.
Tighten securing nut -4- to 10 Nm.
Attach return spring -8-.
Check idling speed and engine governed speed and adjust if necessary.
Notes:
If, after installation the idling speed deviates only a small amount from specification - approx. 200 rpm -, then the installation position is not to be altered.
By moving the throttle lever clockwise by one spline relative to the throttle lever shaft, the engine will race in the idling speed position at approx. 4000 rpm.
By moving one spline anti-clockwise the engine will run at a considerably lower idling speed - approx. 500 rpm - or will not start without the throttle being depressed and cuts out when idling. In such cases correct the position of the throttle lever.
Install radiator with lock carrier.
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.